Stretchable garment with breast supporting structures

ABSTRACT

A garment for support of a wearer&#39;s bust (e.g. a brassiere, bralette, a tank top, or other garment) may include one or more of an elastic under-band, an internal bust support structure, and an external bust support platform for providing additional bust support.

BACKGROUND

There are a variety of different types bras and bra-like garments (e.g. bralettes, tank tops with built-in bras, etc.) available on the market. However, many traditional bras include underwires or bulky support structures in order to provide sufficient support. These support structures may be uncomfortable for wearers, or may not be suitable to wear at certain times (e.g. at night). The problems associated with underwires and other bulky support structures of typical bras or bra-like products are more pronounced for pregnant or nursing women, whose breasts are often swollen and sore. Furthermore, traditional bras and bra-like products are sized using a band and bust measurement, and the fit of the bra or bra-like product is not flexible, making their wear problematic during periods when breast size may fluctuate, such as pregnancy or when nursing.

Seamless bras have been developed to address some of these problems. The material structure of a typical seamless bra is formed from a single tube, constructed of stretchable material that is folded in half, with the two resulting layers then stitched together along a top edge. Alternatively, seamless bras may be formed by folding the material to form an under-band and then finished to form a single layer garment. They do not have seams where multiple parts of the material structure of the bra have been stitched together. Different pieces, such as straps or a back closure, may then be added to the material structure. Additionally, seamless bras typically have molded breast cups and extra knitting for support and in order to contain the bust. Many seamless bras are also wireless. It is because of the way they are constructed, with a lack of seams and underwires and with stretchable material that they tend to me more comfortable for the wearer. However, the seamless bras currently available tend to be suited for women with smaller busts. Women with larger busts require a more supportive bra or bra-like product than those with a smaller bust, and while seamless bras or bra-like products may be worn by women with larger busts, in many instances sufficient support may be lacking.

It is also particularly common for a woman to desire to wear a seamless bra during the first months of pregnancy and during the postpartum period, at which times the breasts may be swollen and sore. As the weight of a lactating breast can be 35% heavier than the weight of a non-lactating breast of the same size, bra products providing adequate support are often desired. Lack of proper support of the breast may even cause damage to the breast tissue in some circumstances.

Providing a bra or bra-like product with sufficient support for larger busted, pregnant, or nursing women is a challenge which often leads to a tradeoff between comfort and support. There exists a need in the art for a bra or bra-like product with the comfort of a seamless bra that also provides the level support and stretch needed for women with a larger bust and/or during periods of time when the bust is larger, heavier, and/or fluctuating in size.

SUMMARY

The invention addresses these and other problems associated with the prior art by providing in one aspect an embodiment of a garment that includes a single piece of stretchable material folded along a mirror line forming a material support structure, where the mirror line forms a lower edge of the material support structure. In this embodiment, the material support structure further defines two layers of material, including an interior layer of material in contact with a wearer when in use and an exterior material layer, laterally-separated cup portions for support of the wearer, and at least one side wing portion. Additionally, this embodiment includes an internal bust support constructed of at least one stabilizing material interposed within the material support structure and extending at least along undersides of the laterally-separated cup portions and the at least one side wing portion, an external support platform for each breast constructed overlaying the interior layer of the material support structure and extending at least along the undersides of the laterally-separated cup portions, and an under-band constructed of at least one elastic material located within the material support structure and extending laterally along the lower edge of the garment.

In some embodiments, a garment consistent with the invention may further include at least one shoulder strap coupling at least one laterally-separated cup portion to a back portion of the material support structure. In some embodiments the back portion may further include a closure. In some embodiments the shoulder straps additionally include at least one laterally-separated cup portion that is removably attached proximate the shoulder strap to allow for nursing or pumping. Some embodiments include an internal bust support constructed from a stabilizing material. In some embodiments the laterally-separated cup portions further comprise molded cups. In some embodiments the external support platform for each breast is constructed from a double layered piece of stretchable material. In some embodiments the external support platform for each breast includes concave top edge. In some embodiments the external support platform for each breast is attached to the material support structure proximate a center line of the garment interposed between the laterally-separated cup portions, proximate the side wing portion, and along a lower edge of the laterally-separated cup portion. Some embodiments also include an internal bust support that is constructed from at least one piece of material.

In some embodiments the internal bust support includes at least one of: a center internal bust support piece positioned along a vertical center line of the garment interposed between the laterally-separated cup portions and curving downward following the shape of the laterally-separated cup portion extending to the center of the laterally-separated cup portion; a side wing internal bust support piece positioned along an outer line of the laterally-separated cup portions and curving downward following the shape of the laterally-separated cup portion extending to the center of the laterally-separated cup portion; and an under-bust internal support piece positioned following a lower outline of the laterally-separate cup positions.

Consistent with another aspect of the invention an embodiment of a garment may include a material support structure that includes opposing interior and exterior material layers and defining laterally-separated cup portions for supporting a wearer's bust when in use. This embodiment also includes an internal bust support constructed of at least one stabilizing material interposed between the interior and exterior material layers and extending at least along undersides of the laterally-separated cup portions of the bust support structure, and an external material support platform overlaying the interior material layer of the breast support structure and extending at least along the undersides of the laterally-separated cup portions of the breast support structure. Some embodiments also may include an under-band constructed of at least one elastic material and extending along a lower edge of the garment.

These and other advantages and features, which characterize the invention, are set forth in the claims annexed hereto and forming a further part thereof. However, for a better understanding of the invention, and of the advantages and objectives attained through its use, reference should be made to the drawings, as well as the accompanying descriptive matter, in which there are described exemplary embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a front view of an example embodiment of a bra consistent with some aspects of the invention, and illustrated in an open position.

FIG. 2 illustrates a rear view of the bra of FIG. 1.

FIG. 3 illustrates a top plan view of the bra of FIG. 1 after partial construction thereof, and illustrating an internalized structure including an example embodiment of an under-band.

FIG. 4 illustrates a top plan view of the bra of FIG. 1 after partial construction thereof, and illustrating an internalized structure including an example embodiment of an internal bust support.

FIG. 5A-5C illustrate top plan views of various components of another example embodiment of an internal bust support to that of FIG. 4.

FIG. 6 illustrates an enlarged rear view of a portion of the bra of FIG. 1, and illustrating an example embodiment of an external support platform.

DETAILED DESCRIPTION

Turning now to the drawings, wherein like numbers denote like parts throughout the several views, FIG. 1 illustrates an example embodiment of a brassiere, or “bra,” 100 consistent with the invention, and shown in an open position with the exterior layer 102 that faces outwardly while in use visible. FIG. 2 illustrates bra 100 in an open position such that the interior layer 202 that is in contact with a wearer when in use is shown. Bra 100 includes laterally-separated cup portions 204, 206 that support the breasts of a wearer when in user. The cups may be padded, molded, contain inserts, or any other constructions known in the art. In some embodiments of the invention the cups may be integral with the rest of the garment; or, in other embodiments the cups may be formed separately and sewn or attached thereto. Each of the cups 204, 206 is adjacent to a respective side wing portion 205, 207 that wraps around the side of a wearer under the wearer's arms. The side wing portions 205, 207 are each adjacent to a respective back portion 208, 208′ of the bra that wraps around the back of a wearer when in use. FIG. 2 is depicted as having separable back portions 208, 208′ that may be secured to one another with a hook and eye closure 210. In some embodiments the closure may include buttons, snaps, hook and loop fastener, or any other closure known in the art. In other embodiments the back portions may form one continuous section, and a closure may be omitted.

The bra of FIG. 2 further includes two straps 212, 214, each strap coupling the top of a cup area 204, 206 to the back of the bra 208, 208′. However, those of skill in the art will recognize that a garment consistent with the invention may be designed with a single strap or without straps entirely. The bra of FIG. 2 also includes a side sling 220, 222 attached to each strap 212, 214 that allows the cup portions 204, 206 to be temporarily disconnected where the straps 212, 214 and cup portions 204, 206 meet to expose the breasts for nursing or pumping. In other embodiments, e.g., for non-nursing or non-maternity applications, a garment consistent with the invention may not contain a side sling such that the cups are directly secured to the straps. Products consistent with the invention may include a bras, bralettes, tank tops or other tops incorporating therein a bra-like structure, or any other garment suitable for incorporating the features of the invention therein. In the illustrated embodiment, bra 100 is a seamless bra. It will be appreciated, however, that the principles of the invention may be applied to different types of bras as well as other types of garments, so the invention is not limited to a seamless bra.

As is standard in the industry of seamless bras, the main material structure of bra 100 may be constructed primarily from a single piece of material that forms the cups, the side wings and back portions of the garment, and in some embodiments, the material may be knitted in a variety of patterns to provide different properties in different areas of the garment. For example, FIG. 2 shows three different knitting patterns: a knitting pattern for the lower edge of the garment 224; an under-bust knitting pattern 226; and, a side wing knitting pattern 228.

The bra 100 is constructed with an interior layer 202 that comes into contract with the wearer while in use, and an exterior layer 102 that faces outwardly while in use. In some embodiments the layers may be constructed from separate, independent pieces of material that are stitched together. In other embodiments, as illustrated in FIG. 3, the layers 102, 202 are created from a single piece of stretchable material folded along a mirror line 302. Stretchable materials may include synthetic materials, including material blends that are designed to stretch at least two ways. As an illustrative example, a stretchable material blend of 90% nylon and 10% spandex may be used. It will be appreciated, however, that there are numerous types of materials, and garments consistent with the invention may be constructed of any suitable materials known in the art.

A garment consistent with the invention may also include additional support structures and components to provide additional bust support, e.g., at least one of and any combination of the following features: an under-band, an internal bust support structure, and an external platform. As will become more apparent below, an under-band may extend laterally across a wearer's torso to allow a garment consistent with the invention to remain flush with the chest, increasing support of the bust. An internal bust support structure may be a support structure interposed between the interior 202 and exterior 102 layers of material at least along the undersides of the cup portions to provide additional support for the bust. An external platform may be a support structure attached to or otherwise overlaying a portion of the interior layer 202 to provide additional support for the breasts. Various embodiments of these features are described in further detail herein, however, the described embodiments are not intended to be limiting and one of skill in the art may recognize various additional embodiments of these features.

FIG. 3, for example, illustrates an example embodiment of the under-band 304. FIG. 3, in particular, illustrates bra 100 in a partially-constructed state, and showing the interior 202 and exterior 102 layers being formed of a single piece of material and capable of being folded along a mirror line 302. Once folded along the mirror line a material support structure may be formed. In some embodiments the material support structure may be the structure of the bra 100, as shown in FIGS. 1 and 2. In other embodiments the material support structure may be further incorporated into another garment, such as, for example, a tank top. Once folded, the mirror line forms the lower edge of the material support structure. In the embodiment of the invention illustrated in FIG. 3, the under-band is incorporated into the construction of the bra itself, and the under-band is placed proximate to and along the mirror line, thus extending along the lower-edge of the bra. In other embodiments, the under-band may be inserted into a void defined between the two layers after the two layers are sewn together. In these embodiments the under-band may not be visible on the exterior of a completed garment, and may be interposed between the exterior and interior layers 102, 202 respectively. In other embodiments, the under-band may added after construction of, and be on the outside of, a garment consistent with the invention, thus making it visible on the exterior of a garment. The under-band 304 may be formed of elastic material and may vary in width. In some embodiments, the band may be about 30 mm wide, although the invention is not so limited. The under-band provides additional support and allows the garment to remain flush against the user's ribcage for optimal support of the breasts.

FIG. 4 illustrates an embodiment of the internal bust support 402. The internal bust support may be sewn into the material support structure interposed between the interior 202 and exterior layers 102 of material, and may not visible upon examination of the exterior layer 204 of a garment consistent with the invention. In some embodiments the internal bust support 402 includes a single piece of stabilizing material (as depicted in FIG. 4). The internal bust support 402 may be roughly shaped like a “w” and may extend along the undersides of the laterally-separated cup portions 204, 206, along the side wing portions 205, 207, and along a central region 404 between cup portions 204, 206. The shape of the internal bust support may allow for maximum support of the bust, in particular the larger, heavier bust. The internal bust support 402 may be constructed of any stabilizing material, for example any rigid or semi-rigid material known in the art. This stabilizing material generally provides more support than the stretchable material of bra 100 itself. The stabilizing material may be adhered or applied to the interior of a garment with channeling, metal or plastic wire, or the like. In some embodiments the stabilizing material used to form the internal bust support 402 may be a stabilizing fabric, such as marquisette, although the invention is not so limited.

In other embodiments the internal bust support 402 may be constructed of multiple pieces (see FIG. 5A-5C). These pieces, taken together are roughly shaped like a “w” and extend along the undersides of the laterally-separated cup portions 204, 206 and along the side wing portions 205, 207—similar to the single piece construction illustrated in FIG. 4. Separate pieces of material may reduce consumption of material. Each piece may also be used individually in a garment consistent with the invention to provide support for the bust. For example, in some embodiments, the internal bust support may only extend along the undersides of the cups, and no internal bust support may be provided in the side wing portions and/or between the cups.

FIG. 5A illustrates a center internal bust support piece 502, which is positioned along a vertical center line 504 of the garment of FIG. 5A in the central region 404 between the laterally-separated cup portions 204, 206. The center internal bust support piece 502 curves downward along the cup portions 204, 206 following the shape of each cup portion and extending to roughly the center of the laterally-separated cup portions 204, 206. FIG. 5B illustrates two side wing internal bust support pieces 506, 508. The side wing internal bust pieces 506, 508 are positioned along the side wing portions 205, 207 respectively and along the outer edge of the laterally-separated cup portions 204, 206 respectively. Together these components allow for containment and support of the breasts along the sides and center of a garment consistent with the invention. FIG. 5C illustrates two under-bust internal support pieces 510, 512 which may be positioned along the lower outline of each laterally-separated cup portion 204, 206. These under-bust internal support pieces 510, 512 provide support for each breast along the sides and center of a garment consistent with the invention. In some embodiments the under-bust internal support pieces may be constructed of a stabilizing material, such as, for example, rigid or semi-rigid material, but the invention is not so limited. In other embodiments the under-bust internal support pieces may be constructed of a channel, rigid tape, or any other rigid support material known in the art. A wire may also be included. Taken together the center internal bust support piece 502, the side wing internal bust support pieces 506, 508, and the under-bust internal support pieces 510, 512 provide added reinforcement to the center area of a garment consistent with the invention containing laterally-separated cups 204, 206 and side wings 205, 207.

FIG. 6 illustrates an embodiment of the external support platform 602. FIG. 6 is an enlarged illustration the bra of FIG. 1 focusing on a single laterally-spaced cup portion 206. The external support platform 602 overlays the interior layer 202 of the material support of the bra, extending along the underside of a first laterally-separate cup 206, and generally may be visible on the inwardly-facing side of the bra. While FIG. 6 only illustrates a single side of the bra of FIG. 1, it is to be understood that a second external support platform would overlay the interior layer 202 extending along the underside of a second laterally-separated cup 204. In some embodiments, the external support platform 602 may be constructed as a double-layered piece of the same stretchable material as the interior and exterior layers of the garment, although the invention is not so limited. In other embodiments the external support platform may be constructed of a single layer of material, or may be constructed from a single or multiple layers of a material different from that of the main material support structure. The external support platform 602 may have any shape along the top edge thereof. In some embodiments, the external support platform may be concave in shape. In other embodiments, the external support platform may be rectangular in shape. The particular size of the external support platform may be determined by an overall size of a garment and the size necessary for a wearer. In some embodiments, the external support platform 602 may be attached to the garment by laminating, stitching, knitting, fusing or by other means known in the art at a center line of a garment interposed between the laterally-shaped cups 504 and at the side wing portion 206. In other embodiments the external support platform 602 may be attached to a garment by stitching at a center line of the garment 504, a side wing portion 207, and along a line running along the bottom of the platform 604. In some embodiments, as shown in FIG. 6, a garment consistent with the invention may additionally have a side sling 222 that allows the cup portion 206 to be temporarily disconnected from a strap (not shown in FIG. 6) of the bra 100 exposing the breast for nursing or pumping, although the invention is not so limited to nursing applications. Generally, a top of the platform 602 is unattached to the rest of the bra such that in use, the platform 602 is cantilevered outwardly from the body of a wearer to support a lower portion of the bust.

A garment consistent with the invention, such as the bra 100, may be constructed by first knitting a main material support structure on a circular knitting machine. In some embodiments the circular knitting machine may knit a single piece of material to comprise both the interior layer 202 and the exterior layer 102. In other embodiments the circular knitting machine may knit a plurality of pieces of material that may be sewn together to form the interior 202 and exterior 102 layers. In some embodiments, the circular knitting machine may be a Santoni circular knitting machine, although the invention is not so limited. In some embodiments, a pleat is formed within the structure during the knitting process. The pleat may be formed such that the outer edge of the pleat is the lower edge of the garment being constructed, thus forming an open channel.

After a material structure is knit, excess material may be removed yielding a rough cut of a garment. The material structure may then be molded based on given specifications of mold depth, time, and heat conditions. In some embodiments, molding will be based on the necessary size of the finished product. The excess material may then be removed along the top of the laterally-separated cup portions 204, 206 and side wing portions 205, 207. In some embodiments, the under-band 304 may be inserted through a channel created by the pleat. The bottom of the under-band 304 may be stitched to the body to hold the under-band in place. In some embodiments this stitch is a zig-zag stitch, although the invention is not so limited.

While the body of a garment consistent with the invention is still open, the internal bust support is laid in place. In some embodiments the internal bust support may be a single piece of material. In other embodiments, the internal bust support may contain multiple, separate, pieces. In some embodiments the internal bust support may be laid in place with a single needle stitch. In other embodiments, the internal bust support may be laid in place by being laminated, stitched, glued, heat sealed or by other means known in the art. In other embodiments the internal bust support may be pinned into place. The interior 202 and exterior 102 layers of the garment are then folded over and stitched together along the cut line of the top of the laterally-separated cup portions 204, 206 and side wing portions 205, 207. In some embodiments a baste stitch may be used to stitch the interior 202 and exterior 102 layers together. In other embodiments, an overlock stitch may be used to stitch the interior 202 and exterior 102 layers together. The edges of the external support platforms, and, if present the side slings, are then stitched together. In some embodiments this may be performed using an overlay stitch, although the invention is not so limited. The external support platforms are then stitched to the garment along the lower portion of the laterally-separated cups and the side wing portions. The side slings, if present, are then stitched to each side wing portion and across the lower portion of the laterally-separated cup portions. In some embodiments the stitching along the lower portion of the cups does not extend the entire length of each cup, rather it extends to approximately the middle of each cup portion. In some embodiments a zig-zag stitch is used to attach the external support platform and the side sling. Finally, if present, straps and a closure (e.g. hook and eye) are then attached.

Other modifications may be made consistent with the invention. Therefore, the invention lies in the claims hereinafter appended. 

What is claimed is:
 1. A garment comprising: a single piece of stretchable material folded along a mirror line forming a material support structure, wherein said mirror line forms a lower edge of the material support structure, the material support structure further comprising: two layers of material, including an interior layer of material in contact with a wearer when in use and an exterior material layer; laterally-separated cup portions for support of the wearer; at least one side wing portion; an internal bust support constructed of at least one stabilizing material interposed within the material support structure and extending at least along undersides of the laterally-separated cup portions and the at least one side wing portion; an external support platform for each breast constructed overlaying the interior layer of the material support structure and extending at least along the undersides of the laterally-separated cup portions; an under-band constructed of at least one elastic material located within the material support structure and extending laterally along the lower edge of the garment.
 2. The garment of claim 1, wherein the garment further comprises at least one shoulder strap coupling at least one laterally-separated cup portion to a back portion of the material support structure.
 3. The garment of claim 2, wherein the back portion of the material support structure further comprises a closure.
 4. The shoulder strap of claim 2, wherein at least one laterally-separated cup portion is removably attached proximate the shoulder strap to allow for nursing or pumping.
 5. The garment of claim 1, wherein the internal bust support is constructed from a stabilizing material.
 6. The garment of claim 1, wherein the laterally-separated cup portions further comprise molded cups;
 7. The garment of claim 1, wherein the external support platform for each breast is constructed from a double layered piece of stretchable material.
 8. The garment of claim 1, wherein external support platform for each breast includes a concave top edge.
 9. The garment of claim 1, wherein the external support platform for each breast is attached to the material support structure proximate a center line of the garment interposed between the laterally-separated cup portions, proximate the side wing portion, and along a lower edge of the laterally-separated cup portion.
 10. The garment of claim 1, wherein the internal bust support is constructed from at least one piece of material.
 11. The garment of claim 10, wherein the internal bust support comprises at least one of: a center internal bust support piece positioned along a vertical center line of the garment interposed between the laterally-separated cup portions and curving downward following the shape of the laterally-separated cup portion extending to the center of the laterally-separated cup portion; a side wing internal bust support piece positioned along an outer line of the laterally-separated cup portions and curving downward following the shape of the laterally-separated cup portion extending to the center of the laterally-separated cup portion; and an under-bust internal support piece positioned following a lower outline of the laterally-separate cup positions.
 12. A garment comprising: a material support structure including opposing interior and exterior material layers and defining laterally-separated cup portions for supporting a wearer's bust when in use; an internal bust support constructed of at least one stabilizing material interposed between the interior and exterior material layers and extending at least along undersides of the laterally-separated cup portions of the bust support structure; and an external material support platform overlaying the interior material layer of the breast support structure and extending at least along the undersides of the laterally-separated cup portions of the breast support structure.
 13. The garment of claim 12, wherein the garment further comprises an under-band constructed of at least one elastic material and extending along a lower edge of the garment.
 14. The garment of claim 12, wherein the garment further comprises at least one shoulder strap coupling at least one laterally-separated cup portion and a back portion.
 15. The shoulder strap of claim 14, wherein at least one laterally-separated cup portion is removably attached proximate the shoulder strap to allow for nursing or pumping.
 16. The garment of claim 12, wherein the laterally-separated cup portions further comprise molded cups.
 17. The garment of claim 12, wherein the back portion of the bust support structure further comprises a closure.
 18. The garment of claim 12, wherein the internal bust support is constructed from a stabilizing material.
 19. The garment of claim 12, wherein the material support platform is attached to the material support structure proximate a center line of the garment interposed between the laterally-separated cup portions, proximate a side wing portion, and along a lower edge of the laterally-separated cup portion.
 20. The garment of claim 12, wherein the internal bust support is constructed from at least one piece of material.
 21. The garment of claim 20, wherein the internal bust support comprises at least one of: a center internal bust support piece positioned along a vertical center line of the garment interposed between the laterally-separated cup portions and curving downward following the shape of the laterally-separated cup portion extending to the center of the laterally-separated cup portion; a side wing internal bust support piece positioned along an outer line of the laterally-separated cup portions and curving downward following the shape of the laterally-separated cup portion extending to the center of the laterally-separated cup portion; and an under-bust internal support piece positioned following a lower outline of the laterally-separated cup positions. 